Logano G615. This manual is available in the English and French language. Please keep this manual for future reference.

Transcription

1 Installation and Service Instructions Low-temperature oil/gas boiler Logano G65 Boilers for oil/gas-fired power burners Read carefully prior to installation and maintenance WARNING: If installation, adjustment, modification, operation or maintenance of the heating system is carried out by an unqualified person, this may result in personal injury or property damage. The directions of this installation manual must be followed precisely. If support or additional information is required, contact a qualified service company, service provider or the gas company O WARNING: Observe the safety instructions of this installation manual before placing the heating appliance in operation. The operating manual is a component of the technical documentation and must be handed over to the operator of the heating system. Explain to the owner or operator how to use the heating system using the operating instructions. Make sure that he has been familiarized with all information required for the operation of the heating system. This manual is available in the English and French language (08/04) US/CA Please keep this manual for future reference.

2 Table of Contents About this manual The appliance has been tested to meet all national requirements in effect on the date of manufacture. The certificates are on file with the manufacturer. This installation and maintenance instructions contain important information for the safe and proper installation, initial start-up and maintenance of the oil/gas-fired boiler Logano G65. These service and installation instructions are designed for specialists, who, due to their vocational training and experience, are knowledgeable in handling heating systems and oil and gas installations. The oil/gas-fired boiler Logano G65 is available in two variants (disassembled and assembled). These installation and service instructions explain the installation and service of both boiler types. Table of Contents Guideline to symbols and safety instructions Guideline to symbols Safety instructions Product description Designated use Operating conditions Compliance with standards and regulations Additional regulations for installations in the Commonwealth of Massachusetts Specifications Scope of delivery Logano G65 Delivery as a pre-assembled block Logano G65 Delivery in loose sections Transporting the boiler Positioning the boiler Tools and auxiliary materials Recommended wall clearances Installing the boiler on a boiler base or foundation... 7 Boiler block assembly Assembly of a boiler block from sections Joining the boiler block assembly (delivery as loose sections) Setting up the boiler block (assembled block) Inserting the supply pipe (parts crate) Installing sensor well (fittings crate) Inserting the lower distribution tube (fittings crate) Leak test Carrying out leak test Seal leaks Boiler water connections Installing draft diverter, baffles, and burner door Positioning the draft diverter Screwing cleanout cover onto rear section Fitting burner door Inserting the flue gas baffles Installation of the boiler jacket Fitting the thermal insulation Fitting the profile rails Fitting side panels and top covers

3 Table of Contents 8 Connecting the boiler on the flue gas side Fitting the vent pipe sealing collar (accessory) Installing a flue gas temperature sensor (option) Installing the control panel Installing the control panel Installing set of temperature sensors Mounting the burner System start-up Filling the system Commissioning the system Start up the control panel Initial burner start-up Commissioning log Shutting down the system Shutting down the heating system via the control panel Shutting down the system in an emergency System inspection and maintenance General information Why is regular maintenance important? Cleaning the boiler with cleaning brushes Wet-cleaning the boiler Checking the operating pressure Refilling boiler water and purging the system Inspection and maintenance logs Troubleshooting burner faults Spare parts Index Appendix

4 Guideline to symbols and safety instructions Guideline to symbols and safety instructions. Guideline to symbols Warnings Signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing damage are not taken. NOTICE indicates that damage to property may occur. CAUTION indicates possible minor to medium personal injury. WARNING indicates possible severe personal injury. DANGER indicates a potential for loss of life. Important Information Additional symbols Symbol Warnings are indicated in the text by a warning triangle and a gray background. In case of danger from electric shock, the exclamation point on the warning triangle is replaced with a lightning symbol. Important information neither indicating personal injury nor damage to property are marked with this symbol. They are separated by lines above and below the text.. Safety instructions Explanation Sequence of steps Cross-reference to other points in this document or to other documents Listing/list entry Listing/list entry (nd level) Table Danger from failing to consider your own safety in an emergency such as a fire Never risk your own life. Your own safety must always take the highest priority. Risk due to oil leaks When using oil as the fuel, national regulations hold the operator responsible for immediately asking a specialist contractor to remedy oil leaks the moment they are discovered. If you smell gas Close the gas shut-off valve. If you hear gas escaping, evacuate the affected area immediately. Open the windows. Do not operate any electrical switches or equipment such as telephones, power plugs and doorbells. Extinguish all open flames. Do not smoke. Do not use lighters. Warn all occupants of the building, but do not ring doorbells. Call your gas utility company and your local heating contractor from outside the building. If necessary, notify police or the fire department. If you smell flue gas Switch OFF the appliance. Open windows and doors. Inform a trained and certified heating contractor. Danger of electric shock when the control panel is open Always de-energize the control panel before working on electrical parts (circuit breaker). Take provisions against unintentional reconnection. Danger of poisoning due to flue gas if supply of combustion air is insufficient Safeguard supply of combustion air. Do not cover or reduce the size of ventilation openings in doors, windows and walls. Safeguard sufficient supply of combustion air also for appliances installed at a later date, e.g. kitchen exhaust fans, clothes dryers, and air conditioning units with vent to the outside. Never operate the appliance if the supply of combustion air is insufficient. Combustion air / room air To prevent corrosion, keep the supply of combustion air / room air free of corrosive substances (e.g. halogenated hydrocarbons that contain chlorine or fluorine compounds). Danger of explosion of flammable gases. Only employ a trained and certified contractor to carry out work on the gas train. Explosive and easily combustible materials Never use or store easily combustible materials (paper, thinners, paints, etc.) near the appliance. Installation, conversion Only have the appliance installed or modified by a trained and certified heating contractor. Never modify any parts that carry flue gas. Never close the outlet of safety valves. Water may be expelled from any safety valve during heat-up. Inspection and maintenance The operator is responsible for safety and environmental compliance of the heating system. Sign a maintenance and inspection contract with a trained and certified contractor, covering an annual inspection and demand-dependent maintenance. This guarantees high efficiency and environmentally sound combustion. 4

5 Product description Instructing the customer Instruct customers about the functions and operation of the appliance. Inform the customer that they must not carry out any modifications or repairs. Only use the boiler for its intended purpose and only when it is in working order. Disposal Dispose of packaging in an environmentally responsible manner. All heating system components that have to be replaced should be disposed of in environmentally-responsible manner at an authorized disposal site. Other important information If the system overheats or the gas supply does not shut off, do not switch off or disconnect the power supply to the pump. Instead, shut off the gas supply somewhere else separate from the heating system. Product description The boiler is a low-temperature boiler for oil or gas power burners with constant or reset boiler water temperature control without minimum return temperature. NOTICE: Risk of system damage from use of incorrect burner. Only use burners that meet the technical requirements of the oil/gas-fired boiler Logano G65 ( Chapter, page 9). The main components of the Logano G65 oil/gas-fired boiler are: The boiler heat exchanger transfers the heat generated by the burner to the boiler water. The boiler jacket and thermal insulation minimize energy loss. The control panel serves to monitor and control all electrical boiler components o Fig. Oil/gas-fired boiler Logano G65 [] Boiler shell (jacket) [] Thermal insulation [] Boiler heat exchanger [4] Control panel assembly 5

6 Product description The Logano G65 oil/gas-fired boiler is supplied with or without a burner You can obtain undrilled or predrilled burner plates (hole pattern depends on burner) as accessories from Buderus. The predrilled burner plate is included in the scope of delivery for the Logano G65 with oil or gas-fired fan-assisted burners. During installation and operation of the heating system, observe all national standards and guidelines! Also observe the details on the boiler rating plate. To prevent boiler contamination, we recommend installing a dirt trap in the water system. Fig. Front jacket [] Burner door panel o As a basic rule, flush existing systems before connecting the boiler. Fuels Logano G65 Heating oil Liquid propane (LPG) Natural Gas (NG) Remark Table Fuels The Logano G65 boiler can be operated with the specified fuels. Select a burner suitable for use with the fuels specified for the Logano G65 boiler. The output figures shown in the Tab. Technical Data are nominal power figures. Carry out maintenance and cleaning procedures annually. Check that the entire system is functioning correctly. Immediately remedy faults. If heating oil is used, shorter maintenance intervals may be necessary depending on the operating time.. Designated use The Logano G65 oil/gas-fired boilers have been designed for the heating of boiler water. The Logano G65 can be operated with oil, gas, and combination burners. For a list of the approved burners, please contact Bosch Thermotechnology Corp. This boiler can be operated with an aquastat, the Logamatic 4000, and other control systems. 6

7 Product description. Operating conditions Thermostream technology is a unique feature of Buderus cast iron boilers. Return water is preheated and mixed within the boiler before it comes in contact with the heating surface of the combustion chamber. The Thermostream technology ensures there is an even temperature distribution in the boiler and avoids condensate forming within the combustion chamber. This unique feature reduces thermal stress, the main cause of failure of traditional cast iron boilers. The advantage of this technology is the maintenance of the minimum operating temperature of the boiler ( Tab. ); this makes the installation of a shunt pump unnecessary. This way, the costs for the pump itself and its power consumption, as well as possible failure costs are saved. The minimum boiler operating temperature as shown in the table below must be reached within 0 minutes and then be maintained while the burner is running. Minimum flow rate Control of all heating zones with Buderus 4000 none External controls (BMS) or with Buderus 4 with ZM 47 or Aquastat control Minimum return temperature F ( C) none Minimum operating temperature oil boiler ) F ( C) (50) Minimum operating temperature gas boilernot DEFINED F ( C) (50) ) 40 (60) ) Maximum supply temperature F ( C) ) /48 4) (00 ) /0 4) ) Maximum operating pressure PSI (bar) 87 (6) For operation with two-stageoil and gas bumers Set the partial load stage to 60 % Time constant of the temperature controller sec 40 Time constant of the monitor/limiter sec 40 Table ) This temperature has to be reached within ten minutes of the burner starting and has to be maintained whilst the burner is firing. ) 65 with partial load < 60 % C ) The maximum supply temperature is F (00 C), if the boiler is operated as hot water boiler. 4) The maximum supply temperature is 48 F (0 C), if the boiler is operated as a hot water generator. A heating zone with a mixing valve improves controllability and is specifically recommended for systems with differing water temperature zones. This operating condition can be easily achieved by the controls monitoring the boiler temperature and reducing the flow rate through the boiler until the required temperature is reached. This is then maintained by continuing to control flow based on the boiler water temperature. The controls can reduce the flow rate by closing the valves on the mixed heating circuits, modulating the boiler primary pumps, closing the motorized butterfly valves or by having a motorized valve in the boiler return on a single boiler installation. The Buderus 4000 series controls can manage this process or it can be completed by the BMS. If it is not possible for the control panel to regulate the flow sufficiently to meet this operating condition, then a shunt pump circuit must be fitted to avoid the type of thermal stress that all boilers would experience in these conditions. This shunt pump circuit can be controlled either with a Buderus 4000 control or with a third-party controller. Failure to ensure that the operating condition is maintained may lead to thermal stress in the boiler and eventual failure of the sections which would be outside the scope of the warranty.. Compliance with standards and regulations Installation and operation of the system must comply with all applicable codes, regulations and statutory requirements. Installation, connection of the fuel supply and flue connector, commissioning, connection of the electrical power supply, servicing and repair may only be carried out by a trained and certified heating contractor. Only registered gas fitters may carry out work on the gas train. The system must be cleaned and serviced once a year. The operation of the complete system must be tested at the same time. Any faults must be corrected immediately. The design and mode of operation of this boiler comply with the American National Standard ANSI Z./CSA4.9, latest edition for Gas Fired Low Pressure Steam and Hot Water Boilers. Other confirmed approvals and certifications are indicated by labels on the boiler. The heat exchanger has been designed and certified in accordance with the ASME Boiler and Vessel Code, Section IV. Installation of the wall mounted condensing gas boiler must comply with all applicable codes and regulations imposed by the national, Federal or local authorities and bodies. If no specific requirements are defined, in the USA, the latest edition of the National Fuel Gas Code ANSI Z./ NFPA 54 applies. In Canada, installation must comply in all respects with the latest edition of the Installation Code for Gas Burning Appliances and Equipment, CAN/CSA-B.49 and the applicable local regulations and requirements for the appliance category. The relevant authorities and regulatory bodies must be informed before installation starts. 7

8 Product description Where required by local regulations, the system must comply with the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-). The hot water distribution system must comply with all applicable codes and regulations. When replacing an existing boiler, it is important to check the condition of the entire hot water distribution system to ensure safe operation. In the Commonwealth of Massachusetts, this appliance must be installed by a licensed plumber and gas fitter. Valves external to the boiler must be fitted with T-handles and condensate piping must be installed in accordance with the State Plumbing Code..4 Additional regulations for installations in the Commonwealth of Massachusetts (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner shall have a period of thirty (0) days to comply with the above requirements; provided, however, that during said thirty (0) day period, a battery operated carbon monoxide detector with an alarm shall be installed. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NPA 70 and be ANSI/UL 04 listed and IAS certified. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (½) inch in size, GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspections, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 48 CRM 5.08()(a) through 4. (b) EXEMPTIONS: The following equipment is exempt from 48 CRM 5.08()(a) through 4: The equipment listed in Section 0 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the board; and Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. (c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM REQUIRED. When the manufacturer of Product Approved side wall horizontally mounted gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for the installation of the equipment and venting shall include: Detailed instructions for the installation of the venting system or the venting system components; and A complete parts list for the venting system design or venting system. (d) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for the venting of flue gases, but identifies special venting systems, the following requirements shall be satisfied by the manufacturer: The referenced special venting systems shall be included with the appliance or equipment installation instructions; and The special venting systems shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions. (e) A copy of all instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or venting design instructions shall remain with the appliance or equipment at the completion of the installation. 8

9 Specifications Specifications The technical data provides information about the output profile of the Logano G /6" (8 mm) 5/" (50 mm) 6" (50 mm) RK 6 7/" (596 mm) 7 57/64" (86 mm) 4 59/64" (5 mm) L F T 54 /" (90 mm) 9 7/" (750 mm) AA VK EL 4 /64" (60 mm) L K L G o Fig. Connections and dimensions [AA] Flue gas spillage [EL] Drain valve (Rp ¾) ) [L K ] Boiler heat exchanger length [L G ] Overall boiler length [RK] Return connection on the boiler ) [VK] Supply connection on the boiler ) ) With the drain valve (EL), you may only drain the system, not fill it. ) The filling of the boiler and the system must be undertaken on a separate connector on the return line. ) The flange corresponds to the order reduced to (DN00), 76 (DN80) or 49 (DN65). 9

10 Specifications Logano G65 Boiler capacity Unit Number of boiler sections Gross output Btu/hr (kw) 95 (570) 4 (660) 5 (740) 8 (80) (90) 40 (00) 69 (0) 98 (00) Net AHRI rating Btu/hr water, gas Net AHRI rating Btu/hr water, oil Input rating gas Btu/hr (kw) 09 (66.) 670 (7.5) 0 (800.0) 9 (886.5) 75 (994.6) 4 (0.0) 4474 (00.0) 485 (97.0) Input rating oil gph (l/h) 9 (6) 0 (8,5) () (,5) (6) 4 (8,5) 5 () 6 () Overall boiler length (L G ) inches (mm) 75 5/64" (96) 8 /64" (096) 89 7/" (66) 95 9/" (46) 0 9/" (606) 09 9/64" (776) 5 6/64" (946) 4/64" (6) Boiler block length (L K ) inches (mm) 7 /64" (804) 77 /" (974) 84 /" (44) 9 7/64" (4) 97 5/64" (484) 04 /64" (654) /6" (84) 7 7/8" (994) Single boiler section size inches (mm) 4 9/64" 64 9/6" 6 45/64" ( ) (B H T) Boiler block transport size (B H L) inches (mm) 4 9/64" 64 9/6" L K ( L K ) Combustion chamber length (L F ) inches (mm) 60 /" (55) 66 47/64" (695) 7 7/64" (865) 80 /8" (05) 86 /6" (05) 9 /" (75) 00 /64" (545) 06 7/8" (75) Combustion chamber inches (mm) 6 49/64" (680) diameter Burner door thickness inches (mm) 5 4 5/64" (45) Weight, net ) lbs. (kg) 5.5 (505) (747) 6.59 (990) 7.5 () 7.66 (475) 8.79 (70) 8.75 (95) 9.4 (447) Boiler water content gal (l) 48.5 (56) 64 (6) 80 (68) (74).5 (80) 7.5 (86) 4.5 (9) 59.5 (98) Gas capacity gal (l) 4.5 (9) 7.5 (07) 99 () 6.75 (7) 54.5 (4) 8.5 (447) 40 (55) (657) Flue gas temperature F ( C) 84 (40) partial load 60 % Flue gas temperature full load F ( C) 8 56 (70 80) Flue gas mass flow rate, oil, F ( C).77 (0.57). (0.778).59 (0.995).97 (0.07).446 (0.479).495 (0.75).59 (0.99).58 (0.4) partial load 60 % Flue gas mass flow rate oil, full load ) lbs./s (kg/s) ( ) Table 4 Technical data and dimensions ( ) ( ) ( ) ( ) ( ) ( ) ( ) 0

11 Scope of delivery 4 Logano G65 Boiler capacity Unit Flue gas mass flow rate, gas, partial load 60% Flue gas mass flow, gas, full load ) CO content, oil CO content, gas Required flue pressure (draft requirement) Fireside pressure drop Permissible supply temperature ) Allowable operating water pressure lbs./s (kg/s) lbs./s (kg/s) 0.4 (0.54) ( ) 0.95 (0.785) ( ) (0.00) ( ) (0.5) ( ) % % 0 PSI (Pa) in W.C. (mbar) F ( C) PSI (bar) (.4).64 (.4).684 (4.).684 (4.) 0 (0) 48 (00 0 4) 87 (6) (0.488) ( ).644 (4.) (0.76) ( ).8045 (4.5) (0.00) ( ).654 (5.4) (0.46).58.8 ( ).58 (5.8) Table 4 Technical data and dimensions ) Weight not incl. packaging material approx. 4 5 % less. ) The details relate to the upper and lower rated output range. ) Safety limit (high limit safety cut-out). Maximum possible supply temperature = safety limit (STB) F ( 8 K). Example: Safety limit (STB) = F (00 C), max. possible supply temperature = = 80 F (00 8 = 8 C). 4) Observe all gas regulations and requirements for your country. 4 Scope of delivery The boiler can be delivered either as a pre-assembled block or in loose sections. After delivery, check all packaging for perfect condition. Check the delivery for completeness. 4. Logano G65 Delivery as a pre-assembled block Component Qty Packaging Boiler heat exchanger Pallet Fittings Crate Assembly parts Crate Jacket pack A Crate Jacket pack B Crate Thermal insulation Foil pouch Table 5 Scope of delivery (block delivery) 4. Logano G65 Delivery in loose sections Component Qty Packaging Front, rear, intermediate section with top Pallet supply connection and burner door Central sections (depending on boiler 5 Pallet size) Fittings basic unit, 9 6 pieces Crate Additional fittings (content depends on Crate boiler size) Assembly parts Crate Jacket pack A Crate Jacket pack B Crate Thermal insulation Foil pouch Tie rods set with spring packages Table 6 Scope of supply (loose sections)

12 5 Transporting the boiler 5 Transporting the boiler Use suitable equipment to transport the individual boiler sections (delivery as loose sections) and other individual parts. WARNING: Risk of injury from improperly secured boiler sections. Use only suitable means of transportation when handling the boiler sections, e.g. a sack truck with strap or heavy duty dolly. Secure the individual boiler sections to prevent them from sliding off when transporting them. NOTICE: Risk of system damage from impacts. The standard delivery of the Logano G65 oil/gasfired boiler contains components that are sensitive to shock. During handling protect all electronic and other components against impact. Please observe the transport instructions on the packaging. NOTICE: Risk of system damage from contamination. If you intend to keep the boiler in storage once it has been assembled, observe the following: Protect the boiler connections against contamination by sealing them off or covering them. Dispose of packaging in an environmentally responsible manner. 6 Positioning the boiler This chapter describes how to properly position the Logano G65. NOTICE: Risk of system damage from freezing. Install the system in a room free from the danger of freezing. Cleaning rags and cloth Fine emery cloth Wire brush -in- oil Solvent (gasoline, mineral spirits) Level, tape measure, chalk, straight edge Boiler assembly tool size. Fig. 4 Boiler assembly tool size. (dimensions in mm) [] Mating flange [] Additional flange [] Compression unit [4] Tie rod [5] Extension [6] Wedge (size.) [L ] /4" (080 mm) [L ] /" (800 mm) Boiler sections 4 5 L L L Assembly tool(s) per boiler hub Extension piece per boiler hub o Length (total) in inches (mm) 9 6 /4 (080) Table 7 Boiler assembly tool size. (complete in the toolbox) For the correct arrangement of the flange when performing the assembly procedure, refer to page Tools and auxiliary materials The following tools and auxiliary materials are required for the boiler assembly (the listed items are not contained in the scope of delivery). Boiler assembly tool. Installation kit (accessory) Steel hammer and wooden or rubber mallet Half-round bastard file Screwdriver (Philips and flat head) Flat chisel, support wedge, flat iron Metric wrenches

13 Positioning the boiler 6 6. Recommended wall clearances 6. Installing the boiler on a boiler base or foundation Š 5 5/4" /4" (400 mm) /6" 7/6" (8 mm) /4" /4" (~ 50 mm)...4" (~ mm) 4 /4" 4 /4" (~ 60 mm) AB + 4" (AB+00 mm) 4" (00 mm) L L A L K AB 4" (00 mm) 6 6 9/64" 9/64" (40 mm) 9/" 9/" (80 mm) 4" (~ 00 mm) o Fig. 6 Base dimensions Fig. 5 Installation room with boiler o A silencing boiler base is available as an accessory from Buderus. Observe the recommended wall clearances for complete opening of the burner door, for boiler installation and for cleaning and maintenance ( Fig. 5 and Tab. 8). The burner door can be hung with the hinges on the right or left. The wall clearance on the hinge side must be at least the burner projection (AB). A distance of AB + 4" (AB + 00 mm) from the wall is recommended. Boiler capacity Clearance A inch (mm) BTU/h (kw) Sections Recommended minimum,944,9,797, /64" (00) 55 /8" (400) (570 80),9,70 4,094,570 (90 00) 6 8 7/64" (000) 59 /6" (500) Table 8 Recommended and minimum wall clearances If you do not observe the recommended minimum wall clearances, you will not be able to use the cleaning kit. Alternatively shorter cleaning devices or wet cleaning may be used. Place the boiler on a 4 inch ( mm) tall base (observe wall clearances). The base must be flat and level. The front edge of the boiler should be flush with the edge of the base. When pouring a foundation for the boiler, use the steel inserts with the following dimensions: 5/6 / 5/6 inches ( mm) or sheet metal with the dimensions 5/6 /64 inches (00 5 mm). Number of boiler sections L (base) inch (mm) L (steel section) inch (mm) 9 65 /4 (670) 57 7/8 (470) 0 7 7/6 (840) 64 9/6 (640) 79 9/64 (00) 7 /4 (80) 85 5/6 4 (80) 77 6/64 (980) 9 /64 (50) 84 4/64 (50) / (50) 9 / (0) / (690) 98 / (490) 6 9/ (860) 04 / (660) Table 9 Base dimensions for angle or sheet metal steel lengths

14 7 Boiler block assembly 7 Boiler block assembly WARNING: Risk of injury from improperly secured boiler sections. Use only suitable means of transportation when handling the boiler sections, e.g. a heavy duty hand truck with strap or a heavy duty hand truck. Secure the individual boiler sections to prevent them from sliding off during transport. 7. Assembly of a boiler block from sections WARNING: Risk of injury from insufficiently secured boiler sections. Secure boiler sections during assembly and take measures to prevent them from tipping over. The installation aid (accessory) is available from Buderus on request o o Fig. 7 Assembled boiler block [] Boiler base or foundation [] Draft diverter [] Rear section [4] Intermediate section with supply connection [5] Intermediate section [6] Tie rod [7] Sequence of installation [8] Front section [9] Burner door with burner plate A distinction is made between delivery as a pre-assembled block and delivered as disassembled sections. When delivered as a block, the boiler sections are already fully assembled and checked for leaks prior to delivery. If the assembled boiler is too large or too heavy to be brought to its final installation location in the building, delivery of the disassembled boiler in sections offers a solution. The assembly of the boiler block from individual sections is described below. For details on final assembly of the remainder of the boiler, see Chapter 7., page 9. Fig. 8 Rear section The assembly of the boiler block is always done from the rear to the front, that is, the rear section ( Fig. 7, []) is always mounted first and the front section ( Fig 7, [8]) is always mounted last. Observe the installation direction arrows of the boiler sections ( Fig. 7, [7]) during assembly! Observe the correct positioning of the intermediate section with top supply connection ( Fig. 7, [4])! Mount the boiler block according to the instructions and figures below! 4

15 Boiler block assembly 7 7. Joining the boiler block assembly (delivery as loose sections) Preparing boiler sections Remove nuts and washers from the studs on the hubs of the boiler sections before attaching the rear section and front section. Put the rear section in place and secure during assembly taking measures to prevent tipping over ( Fig 8 and separate instructions for installation). File down any burrs on the hubs if necessary o Fig. 0 Coating the hub sealing faces [] Sealing face of top hub [] Sealing face of bottom hub [] Packing groove Clean nipple with a rag soaked in solvents or gasoline and coat evenly with sealant o Fig. 9 Filing down burrs on the hub Clean the packing grooves where required using a wire brush and cloth. WARNING: Danger of fire from combustible cleaning agents. When using solvents, avoid open flames, ambers and sparks. Please observe the safety instructions regarding any solvents used. Clean the hub sealing faces with a rag soaked in solvents or gasoline. Evenly coat the hub sealing faces with sealant. The next step involves preparing the nipples that will eventually seal the boiler sections. WARNING: Health hazard from noxious vapors released during material handling, such as solvents, primers or sealant. Ensure adequate ventilation of the installation area. Please note the handling and safety instructions of the product used. Insert nipple directly into the top (size 4, 8/70) and bottom (size, 9/50) hub on the rear section. Strike the nipple with hefty hammer strokes in a cross pattern. The top nipple must protrude approx. /4" (4 mm) and the bottom nipple approx. /4" ( mm) out of the corresponding hubs. Remove any burrs with a file. The packing grooves must be clean and dry for the sealant rope to adhere properly. 5

16 7 Boiler block assembly -/4" (4 mm) 4 Do not let sealant rope overlap at the left and right of the butt joints ( Fig., []). -/4" ( mm) Fig. Driving nipples home Coat the packing grooves with adhesive (primer) o Fig. Inserting sealant rope [] Packing grooves [] Sealant rope [] Butt joints o Prepare the first intermediate section (with top supply connection): File down any burrs on the hub. The packing springs must be clean and dry. Clean if necessary. Clean the hub sealing faces with a rag soaked in mineral spirit or gasoline o Fig. Coat the packing grooves with adhesive (primer) [] Packing grooves Insert the flexible sealant rope on the front of the rear section, starting around the top hub, into the packing grooves, and press in lightly. At the butt joints, overlap the sealant rope by approx. /4" (0 mm) and press firmly together. Unroll the required length of sealant rope from the spool supplied. Peel the backing paper from the sealant rope when inserting into the packing groove (do not stretch) o Fig. 4 Preparing the center section [] Sealing face of the hub [] Packing springs Evenly coat the hub sealing faces with sealant. Coat the packing springs with primer. Position the intermediate section with the supply connection so that the top and bottom hubs fit onto the nipples in the rear section. The directional arrow must point towards the rear. 6

17 Boiler block assembly 7 To make installation easier, place the boiler section to be fitted onto the nipple on the top hub first. Then it is easier to align the boiler section on the bottom hub. Drive first intermediate section onto the rear section using a wooden or a rubber mallet. Before the nipples are inserted in the next intermediate section, the partly-assembled boiler block must be compressed using the boiler assembly tool o Fig. 6 Using the boiler assembly tool [] Boiler assembly tool (bottom hub) [] Boiler assembly tool (top hub) [] Pressure flange (top) [4] Pressure flange (bottom) Place ratchet wrench onto clamping nut and compress boiler sections by tightening evenly. 4 Fig. 5 Pound intermediate section in place [] Supply connection [] Top hub [] Directional arrow [4] Bottom hub [5] Wood or rubber mallet o CAUTION: Danger of accident from material fatigue. Improperly used or poorly maintained assembly tools may fail. Never work directly in front of the assembly tool while it is being tensioned. Ensure that no one is standing in front of the assembly tool. Release and remove the boiler assembly tool. Check nipples are seated correctly. Use boiler assembly tool. ( Fig. 4, page ). Push pressure flange with clamping nuts onto the tie rods. Push a tie rod through the top and bottom hubs on the boiler block. Push mating flanges onto the tie rods and secure each with wedge. Hold the tie rod in the center of the hubs and slightly draw together the compression tools using the clamping nut. NOTICE: Assembly tool damage due to loose screw connections of the tie rods. Always check the tie rods before each use and retighten as necessary. The tie rod is correctly positioned if it is fully inserted and no threads are showing ( Fig. 7, []). Always keep the threads ( Fig. 7, []) clean. Dirty threads may damage the assembly tool during compression. NOTICE: The boiler can be damaged by pulling the boiler sections together incorrectly or due to excessive compression. Ensure that the nipples are positioned straight in the boiler hubs after being pounded in and that they have not been compromised. Never compress more than one nipple joint at a time. Stop compressing the sections when the boiler hubs meet. 7

18 7 Boiler block assembly NOTICE: Damage to system through excessively low contact pressure. Do not compress the spring pack. Only use the spring pack in its original state. Insert the tie rods (with spring packages fitted) into the cast lugs on the top left and right, and bottom left and right, next to the boiler block hubs. Turn and tighten each nut on the tie rods by hand. Now tighten the nuts on the tie rods to ½ turns. Level the boiler block vertically and horizontally on the base/ foundation ( see Chapter 6., page ). Use the boiler section foot wedges provided for this purpose ( Fig. 8, page 8). Remove boiler assembly tool o Fig. 7 Boiler assembly tool. [] Screw connection of the tie rods (disassembled) [] Screw connection of the tie rods (correctly positioned) Fig. 8 shows the intermediate section with supply connection. The nipples for mounting of the next intermediate section are inserted into the corresponding hubs. The sealant rope has already been inserted into the packing groove. As shown for the rear section ( Fig., page 6), here too, the flexible sealant rope is interrupted. The boiler section has been equipped with foot wedges for ease of installation. The boiler section foot wedges are also used later for final leveling of the boiler block o Fig. 9 Inserting the tie rods [] Tie rods (bottom) [] Tie rods (top) [] Tie rod with spring package The next step describes the installation of the supply pipe ( see Chapter 7.4, page 9) o Fig. 8 Using the boiler section foot wedges [] Sealant rope (interrupted) [] Boiler section foot wedge Assemble all other boiler sections as described. The front section is fitted last. After the front section is attached, loosen the assembly tool but do not remove it. First insert the tie rods. 8

19 Boiler block assembly 7 7. Setting up the boiler block (assembled block) Cut the straps. Remove pallet. DANGER: Risk of fatal injury from falling objects. Provide a suitable means of supporting the load. Observe all locally applicable occupational health & safety regulations regarding lifting equipment. 7.4 Inserting the supply pipe (parts crate) For boilers with 9 sections, the supply pipe consists of pieces, and 6 sections pieces. Push the flat gasket over the supply pipe. Push the supply pipe from the front into the top boiler hub. Close off with flange cover. The supply pipe must be fixed in such a way that the holes on the supply pipe are positioned at the correct angle. This ensures optimum distribution of water in the area of the top boiler hub (Thermostream principle). Make sure that the cam []) on the end plate of the supply pipe ( Fig., []) fits in the notch in the top boiler hub ( Fig, [5]) o Fig. 0 Boiler block on pallet [] Securing straps [] Pallet Level the boiler block vertically and horizontally on the base/ foundation. Use the boiler section foot wedges provided for this purpose. After leveling the boiler block, remove the transport safety brace from the top and bottom hub. The following pages describe the installation of the supply pipe and sensor well. You must do both irrespective of whether the boiler is supplied pre-assembled or in separate sections. Fig. Sealing in the supply pipe [] Flat gasket [] Flange cover [] Cam [4] Supply pipe [5] Notch in top boiler hub o Fig. Removing the transport safety brace [] Top hub [] Bottom hub [] Transport safety brace o 9

20 7 Boiler block assembly 7.5 Installing sensor well (fittings crate) Sensor well R ¾ " Seal and install sensor well R ¾ " from the front (length: 4 /64" (0 mm)) into the top R ¾ " tapped hole of the supply connection. Sensor well R ½ " Seal and install sensor well R ½ " from the front (length: 4 /64" (0 mm)) into the lower R ½ " tapped hole of the supply connection. Push the lower distribution tube element with spring (L ) into the bottom boiler hub first. Hook the other lower distribution tube elements (L ) into one another according to the detailed drawing. As the last lower distribution tube element, hook in the one with the handle (L ). Close off bottom boiler hub with flat gasket and flange cover. The length and number of the lower distribution tube elements depends on the boiler size and can be determined using Table 0 below. Fig. Installing sensor wells [] Sensor well R ¾ " [] Sensor well R ½ " o Elements L 8 9/" (480 mm) 5 9/" (650 mm) L 0 5/64" (50 mm) 6 49/64" (680 mm) L 7 /" (450 mm) Table 0 Length and number of the lower distribution tube elements Inserting the lower distribution tube (fittings crate) Mount the tapped hole for the drain connection on the bottom boiler hub behind the flange (edge length 5 /8" (0 mm)) with R ¾ ". Fit customer-supplied boiler drain valve. The customer-supplied boiler fill and drain valve is only used as a drain valve here o Fig. 5 Inserting the lower distribution tube [] Lower distribution tube element L [] Lower distribution tube element L [] Flat gasket [4] Flange cover [5] Lower distribution tube element L o Fig. 4 Fitting the flange [] Fill and drain connection [] Bottom boiler hub (rear) 0

21 Boiler block assembly Leak test Conduct a leak test of the boiler block only when the boiler was delivered disassembled. Pre-assembled blocks are leak tested at the factory. For details of assembling the remainder of the boiler if the block is delivered pre-assembled see Chapter 7.9.4, page Carrying out leak test WARNING: Danger of life from neglecting to follow safety regulations. Observe the applicable national standards, occupational safety provisions and regulations for executing leak tests Seal leaks. If leaky hub connections are discovered during the pressure test, proceed as follows. Remove supply pipe and lower distribution tube. Undo nuts on tie rods and remove tie rods. Separate the boiler block at the leak location by driving (knocking) in flat wedges or chisels between the sections at the points provided at the top and bottom ( Fig. 6). NOTICE: Risk of system damage from overpressure. Ensure that no pressure, control or safety equipment is fitted during leak tests. The leak test must be performed with a test pressure of 5 psi (8.6 bar). Use a suitable pressure gauge to measure the pressure. Drain the water from the fill and drain valve ( Fig. 4, [], page 0), at the water supply connection, or at a leaky hub connection. Close off supply and return connections (supply connection flange with air vent valve). Slowly fill the boiler block with water via the fill and drain connection. Purge the air from the boiler block via the boiler supply connection with purger. Fig. 6 Separating the boiler block o Use new nipples and new sealant rope for the reassembly. Pull the boiler back together and repeat the leak test.

22 7 Boiler block assembly 7.8 Boiler water connections Please observe the following information regarding the boiler connection to the system of pipes. These instructions are important for trouble-free operation. NOTICE: Risk of system damage from leaking connections. All pipe connections to the boiler must be free of stress and tension. NOTICE: System damage due to deposits, local overheating, and corrosion. As a basic rule, clean and flush existing systems thoroughly before connecting new boiler. Install a desludging unit in the boiler return to prevent damage to the boiler. The weld neck flange is fitted to the top boiler hub if the return is connected at a later stage. The weld neck flange and flat gasket are shown. The supply connection flange is required for connecting the supply at a later stage. NOTICE: Risk of system damage from temperature stresses. Install a fill valve on the system side. When the heating system is in operation, do not fill it via the boiler fill & drain valve. Instead, fill it on the system side. 7.9 Installing draft diverter, baffles, and burner door The next step in the assembly process is to install the burner door and draft diverter. The pre-assembled boiler comes with these components already installed Positioning the draft diverter The GP sealant rope (fiberglass cord with silicon casing) which forms a seal is inserted in the draft diverter at the factory. Glue GP sealant rope (approx. 59 /6 inches (500 mm) long) into the groove on the rear section using adhesive. Insert the sealant rope in such a way that its joint is at the top of the groove. Place the draft diverter onto the four threaded studs on the rear section and secure using washers and nuts o o Fig. 8 Positioning the draft diverter Fig. 7 Fitting a flange [] Supply connection flange [] Flat gasket [] Top boiler hub (return connection) [4] Flat gasket [5] Weld neck flange [] Sealant rope joint at the top of the groove [] Sealant rope [] Draft diverter [4] Threaded studs [5] Rear section [6] Threaded studs The supply and return manifolds are included in the Buderus scope of delivery.

23 Boiler block assembly Screwing cleanout cover onto rear section Fig. 9 shows the fully equipped rear section with the cleanout covers on the draft diverter and the cleanout covers on the rear section. GP0Glue GP sealant rope (approx. / inches (800 mm) long) into the groove on the rear section with Silastic adhesive (sealant rope joint at top). Secure the cleanout covers on the rear section with washers and nuts Fitting burner door In the factory, the burner door is mounted with the hinges on the right hand side. For left-hand closing, remove the hinges from the right-hand side and reinstall them on the left-hand side of the burner door. Place a few drops of Silastic adhesive, 6 8 inches (5 0 cm) apart in the packing grooves on the front section. Insert GP sealant rope into the packing groove on the front section with the joint on the right or left hand side. Position the sealant rope on the side. Screw the hinge pins (right-hand) to the boiler front section with M 55 machine screws in each case. For left-hand closing, secure accordingly on the left-hand side. Hook the burner door with the hinge lobes into the hinge pins o Fig. 9 Securing the cleanout covers [] Cleanout cover on the draft diverter [] Cleanout cover on the draft diverter [] Cleanout cover on the rear section [4] Cleanout cover on the rear section 4 Fig. 0 Fitting burner door panel [] Hinge pins (top) [] Sealant rope (side) [] Hinge pins (bottom) [4] Hinge lobe (bottom) [5] Holes in the burner door [6] Hinge lobe (top) o